Free cherry picker 250-hour service checklist

• The MapTrack cherry picker 250-hour service checklist contains 32 checks across 9 sections. Sections covered: Engine, Hydraulic System, Boom Structure, Lubrication, Safety Devices, Platform, Tyres / Wheels, Electrical, Functional Test.
• Engine: change engine oil and filter, check coolant level, check fuel system for leaks, inspect air filter element.
• Hydraulic system: check hydraulic oil level, inspect all hydraulic hoses and fittings for leaks or damage, check cylinder rods for scoring.
• Boom structure: visually inspect boom sections, welds, pins and bushes for cracking, corrosion or excessive wear.

Learn more about maintenance and work orders in MapTrack.

• Operator safety: regular testing of safety devices, emergency lowering and overload cutouts ensures the machine is safe for elevated work.
• Early fault detection: routine inspection of boom structure, welds, hydraulic hoses and pins catches developing issues before they become dangerous.
• Regulatory compliance: documented 250-hour services demonstrate compliance with WHS Regulations 2011 and AS 1418.10 requirements for EWP maintenance.
• Reduced breakdowns: changing oil and filters on schedule, greasing pivot points and checking fluid levels prevents the most common causes of unplanned downtime.
• Extended component life: regular maintenance at the 250-hour interval protects engine, hydraulic and boom components from premature wear.
• Insurance and hire compliance: many hire companies and insurers require documented maintenance records at manufacturer-specified intervals.

• Engine: change engine oil and filter, check coolant level, check fuel system for leaks, inspect air filter element.
• Hydraulic system: check hydraulic oil level, inspect all hydraulic hoses and fittings for leaks or damage, check cylinder rods for scoring.
• Boom structure: visually inspect boom sections, welds, pins and bushes for cracking, corrosion or excessive wear.
• Safety devices: test platform tilt alarm, overload cutout, emergency lowering (battery-powered and manual), ground control override.
• Platform: inspect guardrails, mid-rails, toe boards and gate latch. Check harness anchor points.
• Outriggers / stabilisers: test outrigger operation, check interlock prevents boom operation when outriggers are not deployed (if applicable).
• Tyres / wheels: check tyre condition, pressures and wheel nut torque.
• Electrical: check all lights, beacons, horn and control panel operation.
• Lubrication: grease all boom pivot pins, slew bearing, cylinder pins and turntable bearing per grease chart.

1. Park the cherry picker on firm, level ground with the boom fully retracted and lowered. Engage the park brake and chock the wheels.

   The machine must be on level ground with outriggers stowed (or deployed if required for access) before commencing the service. Lower the platform to ground level and retract the boom fully. This ensures safe access and accurate fluid level readings.

2. Change the engine oil and filter. Check all other fluid levels (hydraulic oil, coolant, brake fluid, fuel).

   Drain the engine oil with the engine warm. Replace the oil filter with a genuine or OEM-equivalent element. Refill with the correct grade and volume. Check hydraulic oil level on the sight glass, top up coolant to the correct mark, verify brake fluid is above the minimum line and check fuel for water contamination.

3. Grease all pivot points, boom pins, slew bearing, cylinder pins and turntable bearing as per the manufacturer grease chart.

   Use EP2 lithium complex grease. Pump each grease point until fresh grease is visible at the bearing seal. Do not over-grease sealed bearings. Common points include boom pivot pins, fly boom pins, platform levelling cylinder pins, slew ring, turntable bearing and outrigger pivot pins.

4. Inspect the boom structure, welds, pins and bushes. Check for cracking, corrosion, deformation or excessive play in pivot points.

   Visually inspect all boom sections from the turntable to the platform. Look for weld cracks (especially at high-stress junctions), paint flaking that may indicate underlying corrosion, pin wear (check for play by rocking the boom at each pin), and cylinder rod scoring. Report any structural concerns immediately and do not return the machine to service until assessed by a competent person.

5. Test all safety devices: platform tilt alarm, overload cutout, emergency lowering system (battery and manual), ground control override and outrigger interlocks.

   Test the tilt alarm by tilting the platform beyond the set angle. Test the overload cutout with a calibrated test weight if available. Test emergency lowering from the platform using battery power and the manual hand pump. Verify the ground control override functions correctly. Confirm that the outrigger interlock prevents boom operation when outriggers are not fully deployed (for outrigger-equipped machines).

6. Inspect the platform guardrails, gate, toe boards and harness anchor points. Check tyre condition, pressures and wheel nut torque.

   Ensure guardrails are secure with no bending or cracking. Confirm the gate self-closes and latches properly. Check toe boards are intact. Verify harness anchor points are not bent, cracked or corroded. Inspect tyres for cuts, bulges, embedded objects and tread depth. Check pressures against the manufacturer specification and verify wheel nut torque.

7. Operate the machine through its full range of functions from both the platform and ground controls. Check for smooth operation, abnormal noises and correct function of all controls.

   Raise, extend, slew and lower the boom through its full range. Test all platform controls and then all ground controls. Listen for abnormal noises from the hydraulic system, slew drive and boom pins. Confirm all movements are smooth and controlled with no jerking or drift.

8. Record any defects or recommendations in the notes section. Set the next service due hours and sign off.

   Document all findings, measurements and any defects requiring follow-up. Set the next 250-hour and 500-hour service due points. Obtain the technician and supervisor sign-off. Attach the completed checklist to the machine record.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• AS 1418.10 (Mobile Elevating Work Platforms)
• AS 2550 (Cranes, Hoists and Winches - Safe Use)
• WHS Act 2011
• WHS Regulations 2011 Chapter 5

• Model WHS Regulations (Safe Work Australia)
• Model Work Health and Safety Act (Safe Work Australia)
• AS/NZS 1418.10:2025, Cranes, hoists and winches, elevating work platforms (Standards Australia)
• AS 2550 series, Cranes, hoists and winches, safe use (Standards Australia listing)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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